Panelboard and electrical power distribution system

ABSTRACT

An electrical power distribution system or panelboard that includes a hollow central body with at least one insulated bus bar and a top non-energized metal mounting surface. A plurality of connection points are distributed along the bus bar for electrical device connections. The connection points are contained inside molded plastic holes or wells, and are electrically connected to the main bus bar. Electrical device connections are accomplished via connectors plugged into the holes or wells. The attachment of electrical devices of various sizes and configurations may be accommodated through the use of spacers.

This application claims benefit of and priority to U.S. ProvisionalApplication No. 61/693,985, filed Aug. 28, 2012, by Dean Latham, and isentitled to that filing date for priority. The specification, figuresand complete disclosure of U.S. Provisional Application No. 61/693,985are incorporated herein by specific reference for all purposes.

FIELD OF INVENTION

This invention relates to an electrical power distribution system. Morespecifically, this invention relates to low voltage panelboards andpower distribution systems with improved safety, ease of manufacture,and universal component compatibility.

BACKGROUND OF THE INVENTION

Panelboards (also known as loadcenters) and power distribution systemsare currently used in many industrial and commercial applications as ameans of distributing electrical power from an electrical source to amultitude of downstream loads (e.g., lighting, outlets, electricalequipment, and the like). These panelboards and power distributionsystems provide a plurality of connection points for electricalcomponents (e.g., circuit breakers) to electrically couple with anelectrical source. Typically, that source is a two or three phase powersupply. As is known in the art, the electrical components are designedto monitor and open the circuit to downstream loads when a predeterminedload is exceeded.

Though the prior art panelboards and power distribution systems areeffective in distributing power, many limitations exist. Due to theirdesign, the prior art systems have “live” electrical connection pointsthat are exposed. These live components pose a risk of shock duringinstallation and maintenance. This is particularly the case when anelectrical component is applied to a system, as these components areapplied directly by personnel “screwing” or “plugging” in conductorparts, which may or may not be “live.” An example of a panelboard withfilling material is disclosed in Latham, U.S. Pat. No. 7,889,480 B2,which is incorporated herein by specific reference in its entirety forall purposes.

There is also an issue related to the manufacture of prior artpanelboards and power distribution systems. Conducting parts on priorart systems are not insulated in an effort to facilitate assembly duringmanufacturing. Non-insulated parts pose a risk for personnel installingor performing maintenance on systems.

Additionally, there is an issue with the architecture of prior artpanelboards and power distribution systems as it relates to electricalcomponent (e.g. circuit breaker) compatibility. Prior art panelboardsand power distribution systems are designed to accept only one type ofcomponent and are not designed to allow all market available products tobe installed. Prior art panelboards and power distribution systems arenot designed with an “open architecture.”

Accordingly, what is needed is a panelboard and power distributionsystem that overcomes the problems discussed above.

SUMMARY OF THE INVENTION

In various exemplary embodiments, the present invention comprises apanelboard and power distribution system adapted to mount andelectrically connect to a plurality of electrical components. Thepanelboard and power distribution system includes a central body portionhaving a top metal surface and at least one bus bar positioned withinthe central body portion. The bus bar has “tabs” that extend into aninsulating body. The insulated connections form isolated connection“wells.” The connection wells allow electrical devices to be connectedto the power bus via insulated “plug in” clamp connectors. Thepanelboard and power distribution system uses an isolated clamp designlocated inside the connection wells for electrical device connectionthat insulates and isolates personnel during installation and operation.The insulated “plug in” clamp connectors are secured with anun-energized “snap” connection.

In another embodiment, the panelboard and power distribution systemcomprises a central bus bar and support structure that is fullyinsulated and isolated. The insulated bus bar further isolatespotentially live electrical parts. Insulating the main electrical busreduces the need for additive insulating parts which allows foreconomical product assembly.

In yet another embodiment, the panelboard and power distribution systemuses a connection “system” that allows unlimited electrical componentcompatibility. The connection system consists of an “open architecture”mounting structure and insulated “plug in” clamp connectors that areplugged directly into the main system bus bar and secured withnon-energized “snap” connections. The connectors are designed to beuniversally compatible with all known electrical devices that aresuitable for use.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a panelboard in accordance with anexemplary embodiment of the present invention.

FIG. 2 shows a top view of the panelboard of FIG. 1.

FIG. 3 shows another perspective view of the panelboard of FIG. 1, withthe top support and main incoming insulator removed. FIG. 3 also showsperipheral bus with insulators removed and “plug in” connectorsconnected to the peripheral bus.

FIG. 4A shows a “plug in” connector with all insulating material intact.

FIG. 4B shows a “plug in” connector with all insulating material“ghosted.”

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In various exemplary embodiments, the present invention comprises apanelboard and power distribution system adapted to mount andelectrically connect to a plurality of electrical components. Thepanelboard and power distribution system includes a central body portionhaving a top metal surface and at least one bus bar positioned withinthe central body portion. The bus bar has “tabs” that extend into aninsulating body. The insulated connections form isolated connection“wells.” The connection wells allow electrical devices to be connectedto the power bus via insulated “plug in” clamp connectors. Thepanelboard and power distribution system uses an isolated clamp designlocated inside the connection wells for electrical device connectionthat insulates and isolates personnel during installation and operation.The insulated “plug in” clamp connectors are secured with anun-energized “snap” connection.

In another embodiment, the panelboard and power distribution systemcomprises a central bus bar and support structure that is fullyinsulated and isolated. The insulated bus bar further isolatespotentially live electrical parts. Insulating the main electrical busreduces the need for additive insulating parts which allows foreconomical product assembly.

In yet another embodiment, the panelboard and power distribution systemuses a connection “system” that allows unlimited electrical componentcompatibility. The connection system consists of an “open architecture”mounting structure and insulated “plug in” clamp connectors that areplugged directly into the main system bus bar and secured withnon-energized “snap” connections. The connectors are designed to beuniversally compatible with all known electrical devices that aresuitable for use.

FIGS. 1 through 4B show one exemplary embodiment of the presentinvention. The panelboard 1 comprises a system top support 2 and asystem bottom support 3. The system bottom support comprises a metalplate that runs under the entire system, while the system top supportcomprises a metal plate that runs over some or all of the system, bothproviding for support, stability and mounting of all components.Mounting feet 4 on the system bottom support 3 may be used for securethe panelboard/power bus distribution system to other structures. Aplurality of securing points 5 may be used to secure the system bottomsupport and system top support together with thereby making a stable andinsulated power distribution system “sandwich.”

The main electrical connection point housing 6 is located at one end ofthe panelboard 1. The housing is insulated. The main electricalconnection point housing comprises a removable cover 7 which allowsaccess to the main electrical connection point(s) 8, as seen in FIG. 3.A number of main electrical connection supports 9 are located along thefront edge of the housing, each comprising an arch-shaped clamp used tosecure the main external electrical connection, thereby ensuring thatthe main electrical connections are stable and secure afterinstallation.

Inside the housing 6, the mechanical (screwed) main electricalconnection points 8 allow power to be supplied to the system, and areattached to the main power bus bar 10, thereby allowing power to bedistributed to peripheral feeder points 11. The main power bus bar 10 isinsulated, and runs the length of the system. The bus bar 10 may besupported by pins 12 inserted into the insulators 13 described below.Peripheral feeder points comprise a “plug in” connector 14 to createelectrical connection points 15 that allow power to feed from the mainpower bus bar 10 to a plurality of electrical devices 16. Electricalconnections are housed in the insulators 13 described below. One or morebus bars may be present.

Electrical devices 16 typically are placed on the top of the system, andenergized by a plurality of electrical “plug in” connectors 14. Devicespacers 17 are designed to space the product apart at a certain “pitch”to make all market components compatible with the system of the presentinvention. The spacer maintains device alignment with electricalconnections when multiple electrical devices are placed on the system.

One side of the panelboard comprises a number of insulators 13 thatisolate the main electrical bus 10 and “plug in” connector 14 connectionpoints. Each insulator comprises several insulated wells 18 where “plugin” connectors 14 are inserted to make electrical connections to themain power bus bar 10.

The electrical “plug-in” connectors 14 comprise a clamp type bus 19housed in insulating material 21 to make electrical connections to themain power bus bar within a plurality of insulated wells 18 contained inthe insulators 13 housing the peripheral feeder bus 11. These allowpersonnel to connect system power to various electrical devices. One endof the “plug in” electrical device connector 14 connects to the mainpower via the clamp type bus connection 19, and the other end connectsto the electrical device 16 through a wire 20 connection (e.g., a copperwire). The wire 20 is joined to the clamp type bus connection 19.

The details of the electrical device connectors may be seen in FIGS. 3and 4, which show some of the connectors with covers and insulators“ghosted” and removed. FIG. 4 shows a “plug in” electrical deviceconnector 16 removed from the panelboard. The connector comprises aninsulating housing 21, which may be plastic. The base of the connectorand clamp type bus 19 is inserted into a corresponding insulated well18. Once inserted, the “plug in” connector may be secured. A securing“catch” 22 secures the pluggable connector 14 to the top of a pluralityof insulators 13 which house the insulated wells 18. The securing catchmay be released from the insulator via standard screw driver applicationallowing for removal of the “plug in” connector.

Thus, it should be understood that the embodiments and examplesdescribed herein have been chosen and described in order to bestillustrate the principles of the invention and its practicalapplications to thereby enable one of ordinary skill in the art to bestutilize the invention in various embodiments and with variousmodifications as are suited for particular uses contemplated. Eventhough specific embodiments of this invention have been described, theyare not to be taken as exhaustive. There are several variations thatwill be apparent to those skilled in the art.

What is claimed is:
 1. A panelboard, comprising: a central body having a top surface, a bottom, and two sides; at least one bus bar positioned within the central body; a plurality of tabs extending from said at least one bus bar into a plurality of connection wells; and a plurality of insulated plug-in connectors adapted to be inserted into said isolated connection wells and be electrically connected to said plurality of tabs.
 2. The panelboard of claim 1, wherein all energized parts of the panelboard are insulated or protected from exterior contact.
 3. The panelboard of claim 1, wherein the connection wells are insulated.
 4. The panelboard of claim 1, wherein the at least one bus bar is insulated.
 5. The panelboard of claim 1, wherein each plug-in connector comprises a clamp connector that removably fastens onto the corresponding tab when a plug-in connector is inserted into a connection well.
 6. The panelboard of claim 1, further comprising a plurality of electrical devices, said electrical devices electrically connected to said plurality of plug-in connectors.
 7. The panelboard of claim 6, wherein said electrical devices are located on the top surface of the central body.
 8. The panelboard of claim 7, further comprising one or more spacers, wherein said spacers are adapted to space the one or more electrical devices apart and maintain device alignment with electrical connections to said plug-in connectors.
 9. The panelboard of claim 1, said insulated plug-in connectors further comprising a non-energized securing catch.
 10. A panelboard, comprising: a central body having a top surface, a bottom, and two sides; a central bus bar positioned within the central body portion; a plurality of insulators extending along one side of said central bus bar, each insulator comprising a plurality of isolated connection wells; a plurality of bus bar tabs extending from said central bus bar, each bus bar tab extending into a corresponding isolated connection well; and a plurality of insulated plug-in connectors adapted to be inserted into said isolated connection wells and be electrically connected to said plurality of bus bar tabs.
 11. The panelboard of claim 10, wherein each plug-in connector comprises a clamp connector that fastens onto the corresponding tab.
 12. The panelboard of claim 1, further comprising a plurality of electrical devices, said electrical devices electrically connected to said plurality of plug-in connectors.
 13. The panelboard of claim 12, wherein said electrical devices are located on the top surface of the central body.
 14. The panelboard of claim 13, further comprising one or more spacers, wherein said spacers are adapted to space the one or more electrical devices apart and maintain device alignment with electrical connections to said plug-in connectors.
 15. The panelboard of claim 10, said insulated plug-in connectors further comprising a non-energized securing catch.
 16. A panelboard system, comprising: one or more plug-in connectors, each plug-in connector comprising: a top and a bottom, the bottom comprising a clamp connector adapted to slide over a bus bar tab connection point inside an insulated well on a panelboard; a connection wire extending from the top of the plug-in connector; and a non-energized security catch extending from the top of the plug-in connector, adapted to secure the plug-in connector within the insulated well.
 17. The panelboard system of claim 16, further comprising an insulated bus bar within the panelboard, wherein a plurality of bus bar tabs extend from one side of said insulated bus bar to a plurality of insulated wells.
 18. The panelboard system of claim 16, further comprising a plurality of electrical device receptacles located on the panelboard.
 19. The panelboard system of claim 18, wherein the electrical device receptacles are the same standard size.
 20. The panelboard system of claim 19, further comprising a plurality of spacers to allow electrical devices of different sizes and configurations to be used with the panelboard system and aligned with corresponding plug-in connectors. 